Closed loop tracking system using signal beam

ABSTRACT

The invention is a system and method for heliostat mirror control. Here, each heliostat mirror generates a low intensity “signal beam”, directed at an angle off from the heliostat mirror&#39;s high intensity and sensor blinding “main beam” of reflected solar energy. The low intensity signal beams may be created by reflecting a small portion of the incident solar light at an angle from the main beam, by reflected artificial light, or from lasers shinning onto mirrors from known locations. The signal beams are detected by optical sensors mounted way from the main heliostat receiver focus, and can be used in a closed loop control system to efficiently ensure that individual heliostat mirrors in a heliostat array accurately track sunlight and direct the sunlight to a central receiver. Because heliostat mirrors need not be taken “off sun” for positioning, the system allows heliostat arrays to be run at high efficiency.

This application is a Continuation of U.S. patent application Ser. No.14/677,860, filed on Apr. 2, 2015, which is a Divisional of U.S. patentapplication Ser. No. 12/488,447, filed on Jun. 19, 2009, which claimsthe benefit of U.S. Provisional Patent Application 61/132,794, filedJun. 20, 2008, the specifications of which are herein incorporated byreference.

BACKGROUND OF THE INVENTION

Field of the Invention

One or more embodiments of the invention are directed to the field ofsolar tracking systems. More particularly, but not by way of limitation,embodiments of the invention provide systems and methods for keeping anarray of heliostat mirrors properly oriented towards a solar receiver.

Description of the Related Art

As world oil supplies dwindle, and demand for energy increases,heliostats and other mirror based solar collection devices are becominga widely utilized method of energy production. A heliostat is astationary device that tracks the movement of the sun. The heliostattypically contains a mirror that is oriented throughout the day toredirect sunlight towards a receiver. In large-scale solar energyinstallations, an array of heliostats are arranged to converge the sun'senergy onto the receiver. When many heliostats direct sun energy to thesame receiver, this receiver is generally referred to as a “centralreceiver”.

These heliostat arrays generally contain many thousands of mirrors, andmaintaining alignment of these mirrors over time towards the centralreceiver is a problem that is regularly encountered. In some solarinstallations, various types of mirror orientation devices, such asvarious actuators, control the orientation of the heliostat mirrors.These actuators are generally motion control devices such as motors,servomechanisms, clockwork mechanisms, and the like that are configuredto control the orientation of the heliostat mirror relative to the sunand the receiver. In some instances the actuators are under the controlof one or more computers.

In an ideal scenario, each heliostat within the array is positioned tofocus the sun's rays onto a central receiver for purposes of heating thecentral receiver to extremely high temperatures. In many commercialsolar installations, the central receiver generally contains a heatreceiving medium, such as water or salt. Once heated, the heated mediumtravels through a heat exchanger, where the heat is used to createsteam. The steam in turn may be used to operate a steam turbine andcreate electrical energy. Alternatively, the concentrated solar heat andlight can be used to generate electricity by other processes, or use theconcentrated solar heat and light to perform other useful tasks.

Using a larger number of heliostat mirrors in an array, all focused ontothe same central receiver, typically improves efficiency because moresolar energy can be collected and used by the same receiver. As aresult, although heliostat arrays can be created using as little as oneheliostat mirror and one receiver, typical heliostat arrays contain manythousands of individual heliostats, often arrayed over several or moreacres of land.

One problem that negatively impacts heliostat performance is the problemof directing the reflected sunlight from the various heliostat mirrorsonto the same desired region of focus on the central receiver throughoutthe day, and throughout the year. As the time of day varies and as thetime of year varies, the angle of the sun in the sky varies, and thusthe heliostat mirrors must be continually repositioned to keep directinga maximum amount of reflected sunlight onto the central receiver. Giventhat the heliostat mirrors may be located some distance away from thecentral receiver, even minor errors in mirror orientation can cause thereflected sunlight to miss the receiver, thereby causing the heliostatarray as a whole to function with suboptimal efficiency. Althoughheliostat mirrors are usually controlled by calibrated actuators, thecalibration of the actuators may drift with time, causing pointinginaccuracies.

In theory, the orientation of the main beam of reflected sunlight from agiven heliostat mirror onto a central receiver can be detected by simplyplacing sensors on the central receiver, and monitoring the deviation ofany given heliostat's main beam from the ideal location on the centralreceiver. In practice, however, this simple approach is impracticalgiven that as the number of heliostat mirrors increases, the largeamount of light and heat on the central receiver will tend to overwhelm(destroy or blind) any sensors placed near the beam focus.

To cope with this problem, heliostat mirror actuators and controlsystems can also be partially calibrated by a process of orienting oneor more heliostat mirrors to an “off sun” orientation (i.e. the mirrorsare not directed at the central receiver), calibrating the heliostatactuators in at least the off sun mode, and then returning the heliostatto the “on sun” orientation. However, using the man beam from even oneoff sun oriented heliostat can be problematic because the high intensityof even one main beam can still tend to overwhelm optical sensors anddigital cameras, resulting in lower accuracy, and additionally, the offsun mode of the heliostat is at best a surrogate for the heliostat'ssetting in the on-sun mode.

For at least the reasons set forth above improved methods forpositioning heliostat mirrors are desirable.

BRIEF SUMMARY OF THE INVENTION

One or more embodiments of the invention are directed to a closed loopfeedback system and method for heliostat mirror control. Various aspectsof the invention are based on the insight that although the solar lightenergy in the main beam reflected from the heliostats is too intense toallow for a practical closed loop feedback control system, if eachheliostat mirror could instead be used in a closed loop control systemrelying upon a much lower intensity “signal beam” that correlates withthe main beam, but is directed to a location other than the centralreceiver, then the problem of overwhelming the positioning sensors canbe avoided.

One or more embodiments of the invention utilize this signal beamconcept. Here, various suitable methods of signal beam generation aredisclosed, along with various sensor configurations, and methods andalgorithms to control the orientation of heliostats and heliostat fieldsare also given.

This closed loop system is a substantial improvement over prior artmethods, because it allows the heliostat array to be run at higherefficiency without the need to take one or more heliostat mirrors to anon-operative “off-sun” location for calibration purposes, and the lowerintensity signal coupled with the ability to do the calibration andcontrol in an “on sun mode” allows for higher accuracy.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other aspects, features and advantages of the inventionwill be more apparent from the following more particular descriptionthereof, presented in conjunction with the following drawings wherein:

FIG. 1 illustrates an array of heliostats configured in accordance withone or more embodiments of the invention. These heliostats redirectlight to a tower-mounted receiver or other target, where the energy isabsorbed and converted to steam, electricity, or other usable form.

FIG. 2 illustrates how various types of “signaling mirrors” may bepositioned in accordance with one or more embodiments of the inventionon the main heliostat mirror to generate a low intensity signal beam atan angle different from that of the main beam.

FIG. 3 illustrates one way in which signaling beams from differentheliostat mirrors may be distinguished from each other in accordancewith one or more embodiments of the invention. Although here, for easeof visualization, each signaling mirror is shown generating a differentgeometric shape, in practice other distinguishing methods, such asblinking, shutters, or other optical signal modulation methods, may beused.

FIGS. 4a-c illustrates more details of how the relationship between thesignaling beams and the main beams may be determined in accordance withone or more embodiments of the invention, and used in an automatedclosed-loop system to properly orient heliostat mirrors.

FIG. 5 illustrates an example of a closed-loop algorithm used inaccordance with one or more embodiments of the invention to properlyorient an array of individual heliostat mirrors on a one-heliostatmirror at a time basis.

FIG. 6 illustrates an embodiment of the invention in which the signalbeams are produced by one or more artificial light sources.

FIG. 7 illustrates an embodiment of the invention, in which digitalcameras map the (x,y) coordinates of the reflected artificial lightsources in the heliostat Cartesian coordinate system, thus achievingalmost a 100 x accuracy improvement in angular determination.

FIG. 8 illustrates an embodiment of the invention in which theartificial light sources are mounted on rotating bars, with the barorientation determined by encoders, thus allowing the artificial lightto scan over different portions of the heliostat mirror surface.

FIG. 9 illustrates an embodiment of the invention in which a reflectingelement with a rotating mask is used to achieve a periodic signal beamwhich may be used to distinguish signal beams from main heliostat beams.

DETAILED DESCRIPTION OF THE INVENTION

At the most general level, one or more embodiments of the invention aredirected towards a system and method for positioning a heliostat mirrorwithin an array of heliostat mirrors so that a main beam of incidentsunlight reflected from said heliostat mirror converges onto a singleregion of a receiver. The system and method is implemented in accordancewith one or more embodiments of the invention as a closed loop feedbacksystem and method, but it can be used in an open loop manner if this isdesired. In the following description, numerous specific details are setforth in order to provide a more thorough understanding of embodimentsof the invention. It will be apparent, however, to an artisan ofordinary skill that the present invention may be practiced withoutincorporating all aspects of the specific details described herein. Inother instances, specific features, quantities, or measurements wellknown to those of ordinary skill in the art have not been described indetail so as not to obscure the invention. Readers should note thatalthough examples of the invention are set forth herein, the claims, andthe full scope of any equivalents, are what define one or moreembodiments of the invention.

In one or more embodiments of the invention, the heliostat mirror isinduced to emit or reflect a low intensity signal beam to one or moresensors, usually optical sensors, photodetectors, digital cameras, andthe like, placed in a location outside of the receiver. In order toallow the sensors to be operated at a location other than the receiverlocation (which typically will be operating under conditions of heat andlight that would destroy the sensors), the low intensity signal beamwill be concurrent and/or simultaneous with the main beam, but offsetfrom the main beam. That is the signal beam will be directed at orobservable from an angle offset from that of the main beam.

In order for aspects of the invention to operate, for each heliostat,there is a known relationship between the angle of the heliostat's lowintensity signal beam, and the angle of the heliostat's main beam. Thisrelationship is generally determined by a calibration process but may bepredefined. Once the calibration is determined, the low intensity signalbeam on the one or more optical sensors can be used to determine if theheliostat mirror is positioned properly. That is, so that a main beam ofthe incident sunlight reflected from the heliostat mirror converges ontothe desired region of a receiver. This desired region of the receivermay be a single region on the receiver, and the heliostat beams areideally calibrated to converge on this single point. Alternatively, thedesired region of the receiver may be the region allocated to aparticular heliostat or group of heliostats, with different heliostatsilluminating different regions of the receiver in order to heat thereceiver more uniformly or from different orientations.

There are a number of different ways to cause or induce a heliostatmirror to emit a suitable low intensity signal beam. In one or moreembodiments of the invention, sunlight is used in conjunction withsupplementary optical elements (e.g. small angled mirrors) mounted orcoupled to the heliostat mirror, that cause the sunlight to produce alow intensity signal beam at an angle that diverges from the main beam.Other approaches are also feasible. In other embodiments of theinvention, the heliostat mirrors may be illuminated with artificiallight from an angle other than the sun incident angle, and the reflectedartificial light may be used as a low intensity signal beam.Alternatively, or in addition, collimated light sources, such as lowintensity diode lasers, may be shinning onto the heliostat mirrors fromknown locations, and the emitted artificial light reflection used as alow intensity signal beam.

In one or more embodiments of the invention, the low intensity beam iscreated using sunlight, and supplementary optical elements mounted on oradjacent to the heliostat mirrors, is described. Many of the systems andmethods here, in particular the sensor closed loop feedback system andmethods, may also be used for the other embodiments of the invention aswell. Thus the aspects described here are not limited solely for usewithin this embodiment of the invention.

FIG. 1 shows an array of heliostats (100) configured to redirect sunlight to a tower-mounted receiver (102) or other target where the energyis absorbed and converted to steam, electricity, or other usable form.The heliostats in the one or more embodiments of the invention includeone or more mirrors (104) that receive incident sun light (106) andreflect the majority of the sun light to the receiver (102). Theorientation of the mirrors (104) is dynamically updated with actuators(110) to account for the movement of the sun over the course of the day.A beam of light (108) reflected from a heliostat mirror to the receiveris referred to herein as a “main beam.” To capture the maximal amount ofenergy from the heliostats and convert that energy efficiently, it maybe desirable for the main beams from each of the heliostats to convergeon a single region (112) of the receiver (102), also called theconvergence point. This requires that the orientation of mirrors (104)be precisely known and periodically calibrated to ensure the heliostatstrack the sun and their main beams continually focus light on thereceiver (102). In accordance with this exemplary embodiment, aplurality of the heliostat mirrors also include relatively small opticalelements (114) that redirect a relatively small fraction (116) of theincident light (106) to an array of digital cameras (120) on target(118) for purposes of precisely determining the orientation of theheliostat mirrors. A small optical element (114) is referred to hereinas a “signal mirror,” and a small beam of light (116) reflected from oneof the small optical elements is referred to herein as a “signal beam.”

In this exemplary embodiment, the signal mirror (114) is a small facetof mirror mounted on or otherwise incorporated into a substantiallyplanar heliostat mirror (104). The signal mirror (114) can either beattached to the main mirror and thus obscure a small portion of the mainmirror and/or be mounted adjacent to the main mirror (but coupled to themain mirror), and thus not obscure the main mirror. The normal vectorthat characterizes the orientation of the signal mirror is differentthan the normal vector associated with the heliostat, thereby making themain beam (108) and the signal beam (116) diverge from one another asthey propagate from the heliostat (104). The main beam (108) isgenerally incident on the receiver (102) while the signaling beam (116)is concurrently incident on a “signal beam target” (118) that is below,above, or adjacent to the receiver (102). In one or more embodiments ofthe invention, the signal beam target (118) contains one or more digitalcameras (120) (here the terms digital camera and digital video camerawill be used interchangeably, because often it will be desirable toacquire digital images at frequent time intervals) that are orientedtoward the array of heliostats. The cameras generate output images fromwhich the signal beams (116) are detected and the heliostat mirrororientations computed. The computed mirror orientation information isthen used as a closed-loop feedback signal to determine if theheliostats are tracking the sun and accurately aiming main beams on tothe receiver (102).

Note that the invention may also use optical sensors and image capturedevices. The term optical sensor encompasses digital cameras, but alsoincludes non-image detecting photodetectors as well, such as an array ofphotodetectors that may not necessarily use focusing lenses and orfocusing mirrors. Similarly, the term optical sensor also encompassesimage detection devices as well. Such image detection devices alsoencompass digital cameras, but may also encompass analog video camerasand even cameras that utilize chemically based film methods.

The further away the digital cameras (120) (which often may be a digitalcamera array) are from the signal mirror (114), the greater the sunspread (Illustrated in FIG. 4a (417)) will be. That is, differentdigital cameras (120) at different positions on target (118) will detectthe signal beam (116) from a given signal mirror (114) to a greater orlesser extent, depending upon how close the particular digital camera isto the centroid or point of highest intensity of the particular signalbeam (116). Referring now to FIG. 4c which illustrates that differentcameras may sample different lux levels from the same signal beam thatis reflected from the signal mirror. The gradation in the intensity ofthe signal beam is directly correlated to the distance the signal beamtarget is from the signal mirror. At a point closest to the signalmirror (420) the reflected light is clearly delineated from the naturalsunlight. As the distance from the signal mirror (420) increases the luxlevels of the reflected light begins to have a diffuse edge that resultsfrom the sun spread (417). At point 422, for example, the reflectedlight has a diffuse edge but retains an even level of intensitythroughout the center point of the reflected light. Further from thesignal mirror at point 424 the point of highest intensity in thereflected light is more isolated at an apex (426). In embodiments of theinvention where a plurality of digital cameras (427, 428, 429 and 430)capture the signal beam reflected from the signal mirror, each cameramay obtain a different intensity level for the same signal beam. Whenthis occurs digital image analysis is employed to compare differentimages and sample the intensity of reflected light (424). In the exampledepicted, digital camera 427 samples at point A, digital camera 428samples at point B, digital camera 429 samples at point C and digitalcamera 430 samples at point D. The intensity information obtained fromthe sampling is then utilized to observe or determine centroid 426 whichis indicative of the point of highest intensity in the signal beam. Thecamera or cameras closest to 426 are then utilized to determinepositioning of the heliostat.

Note that the drawing of the digital cameras (120) shows an array ofdifferent cameras (121) separated by a distance between the digitalcameras. In one or more embodiments of the invention, it may be usefulto use digital image analysis to compare different images of the signalmirrors (114) from different digital cameras (121) in array (120),determine which particular digital camera is closest to the centroid ofa particular signal mirror (114), and compute the signal beam (FIG. 4c(424)) distribution across multiple digital cameras (121). The signalbeam distribution (FIG. 4a , (417)) and/or the location of possibleedges in the signal beam can then be utilized in subsequent analysis.The size of the signal mirror and distance from the receiver dictate howmany cameras are needed on the signal beam target to make sure thatcentroid for each signal beam is observed.

One useful distribution of cameras (120) in the array of cameras is adistribution with cameras placed apart at distances equal to about halfof the signal beam sun-spread or signal beam divergence. Thus in one ormore embodiments of the invention, multiple cameras will look at thesignal beam, deduce the center of the signal beam, evaluate the signalbeam spread, and factor in the size of the signal mirror and thedistance to the signal mirror in the analysis.

In one or more embodiments of the invention the system uses multiplecameras or sensors (120) to analyze the distribution of the signal beamas a function of distance geometry (i.e. camera position) and time (i.e.when the camera image was acquired). This is because the angle of thesun in the sky varies as a known function of time, and this can provideadditional information to help calculate exactly which signal mirror isproducing a particular signal beam. For example, geometricconsiderations show that mirrors closer to the cameras (120) willproduce signal beams with generally smaller spread (FIG. 4, (417)) thatvary slower as a function of time, while mirrors further from cameras(120) will produce signal beams with a generally broader spread that mayvary more rapidly as a function of time.

The shape of the signal beam target (118) and digital camera array (120)may vary depending on the layout of the heliostat field. The shape ofthe signal beam target (118) is such that it provides a region uponwhich each heliostat within the array of heliostats will reflect itssignal beam onto the signal beam target throughout the day so long asthe main beam is aligned with the receiver. While the shape will varydepending on the layout of the heliostat array it is advantageous to usea size that permits the mirrors furthest out in the field to reach thesignal beam target when properly aligned as well as the mirrors closestto the receiver. Since the signal beams will travel across differentpositions on the signal beam target throughout the day as the angle ofthe sun changes the size of the signal beam target needs to be largeenough to account for such movement throughout the day and throughoutthe seasons. In one or more embodiments of the invention the signal beamtarget is given a shape that resembles a “kidney bean” in order toaccommodate the distribution of heliostat mirrors in many typicalheliostat arrays. Other shapes are also well within the scope and spiritof the invention as any shape that provides a surface area large enoughto receive the reflected signal beams will suffice.

As depicted in FIG. 2, the “signaling mirror” (114) encompasses avariety of light reflecting, light refracting, and light dispersalelements, and thus can be implemented in various ways. In addition tothe signaling mirror (114) previously discussed in FIG. 1, the opticalelement can include a small prism (not shown) (having an angle ofapproximately 1 degree or any other suitable angle for achieving thedesired effect) that is mounted to the heliostat mirror. The signalmirror may also be concave or convex depending upon the level ofdiffusion or focus desired at the signal beam target. If desired forpurposes of focusing the spread of the signal beam lens elements may bepart of the signaling mirror. A diffraction grating (200) may also beemployed as an optical element, in which case the signal beam (116) maybe spread over a range of angles and wavelengths, which may facilitateprecise determinations of mirror angles. The diffraction grating spreadsout the reflected light periodically over a broader angle than otherembodiments that decays in intensity as the reflection moves off axis.Given that the reflected light from the diffraction grating is broaderthan a prism or mirror, this embodiment enables the digital camera topickup variations in color or intensity that enables repositioning ofthe heliostat mirror across a broader range of angles than otherembodiments. Another exemplary optical element includes a small mirrorfacet (202) mounted on top of a wedge, the faces of the wedge beingseparated by about 1 degree or any other angle suitable for achievingthe desired effect. In still other embodiments, the optical elementincludes a Fresnel lens (204)/mirror combination, or alternatively asignal mirror with slight curvature in its surface to better control thedispersion of the signal beam, and allow it to arrive at target (118)and digital cameras (120) with less dispersion and/or tighter focus. Thewidth and height of an optical element (114), (200), (202), 204) isgenerally substantially less than that of the main heliostat mirror,typically less than 1/50 of the heliostat mirror area, and often no morethan two or three inches in diameter (5-8 cm). This is substantiallysmaller than the heliostat mirror (104) area of one or more squaremeters. Alternative signal beam offset degrees and signaling mirrordiameters may be utilized while keeping with the spirit of the inventionset forth herein. The larger the signal beam mirror the more light.

The exact angle of the offset between the signal beam from the signalmirror and the main beam from the main mirror will differ depending uponthe layout of the heliostat field and the optical sensors. In someconfigurations, where the target (118) and digital cameras (120) aremounted close to the receiver (102), then a narrow offset, such asbetween ¼ degree and 3 degrees may be suitable. In other configurations,where the target (118) and digital cameras are mounted far away from thereceiver (102), then more substantial offsets, up to 180 degrees, may beappropriate. In principle, (for example if the signaling mirror (114) isa prism), the target (118) and digital cameras (120) could even bemounted on the other side of the heliostat field. As such any variationin the angle of offset that provides the desired effect is within thescope and spirit of the invention.

The position/orientation of the signal beam (116) is fixed or otherwisecorrelated to the main beam (108) due to the fixed relationship betweenthe signal mirror (114) and the heliostat mirror (114). For any givenincident light angle (106), the exact angle between the two beams (108),(116) can be determined using, for example, a jig or a process that putseach main beam on the main beam target (i.e., receiver) (102) and thenlocates the signal beam (116) on the signal beam target (118). Thedisplacement of the two beams (108), (116) will vary based on the timeof day and the time of year, but this variation can be computed orretrieved from a sun position table, for example. Once the relativeposition of the main beam (108) and the signal beam (116) are known, thesignal beam's position (116) can be used as part of the closed loopfeedback tracking scheme of the present invention.

Returning to FIG. 1, in one or more embodiments of the invention, theresolution of the digital cameras (120) is sufficient to resolve thesignal beams as separate light sources. Although some contemporarytracking techniques employ digital cameras to calculate the orientationof the heliostat mirrors, the cameras in these prior art approachesattempt to concurrently sense the main beams (108) of multipleheliostats. Light spots from the different main beams are extremelybright and overlap one another, which can present a challenge whenattempting to make accurate angular orientation determinations. In oneor more embodiments of the invention, the signal beams (116) are moresuitable for closed-loop tracking due to their relatively small size andlow light level.

During operation of the solar thermal power plant described herein, thecameras (120) incorporated into the signal beam target (118) continuallyor periodically capture images from which the orientation of theheliostat mirrors (104) are determined. The image data is processed toidentify signal beams (116) from background noise, identify theheliostat mirrors (104) associated with individual signal mirrors (114),and determine the orientation of each heliostat based on the location ofthe signal beam (116) on the target (118). There are multiple ways thatthe signal beams (116) can be identified. They can, for example, beidentified by having a cluster of cameras (120) look out at all thebeams, and the cameras can tell which beam it is viewing by its angle orposition in the field. The signal beams can also be identified by havingother sensors within or at the second target (118). The signal beams canalso be identified by having a camera or other sensor (122) looking atthe target.

FIG. 3 illustrates a detail of the signal beams (116) impinging upon thetarget (118). To distinguish which signal beam (116), and thus, whichheliostat mirror (104), (114) is being observed when there are manybeams at once, the signal beams (116) can either each have differentshapes (300) (encoded into the mirror or prism or diffraction gratingcreating that signal beam) or the signal beams can be encoded byblinking or darkening all or single signal beams (116) at a time. Thiscan be done with a shutter, either electrical or mechanical, or viaanother mechanism to momentarily redirect or turn off a signal beam orgroup of signal beams so that it is clear to distinguish what signalbeam corresponds to what heliostat mirror. Other mechanisms may includesignal mirror (114) vibration mechanisms, such as piezoelectric orelectromagnetic vibration mechanisms, and so on.

The shutter or electrical or mechanical mechanisms may be positioned inone or more embodiments of the invention near the optical element (114),(202), (204), (200). Other ways in which the signal beam may bemodulated (signal beam modulation) include vibration at one or moredefined frequencies or amplitudes, polarization changes, and the like.In some embodiments, it may be useful to impress a digital code signalonto the signal beam (116) that directly encodes the identificationnumber of the individual heliostat onto the signal beam. Varying colorsmay also be assigned to each signal beam in order to facilitate theunique identification of each signal beam.

Once the heliostat mirror (104) associated with a signal beam (116) isidentified, the orientation (and/or position) of the heliostat mirrorcan be adjusted (for example via actuators (110)) to drive the signalbeam (116) to the correct position in order to get the main beam (108)in the desired position (112). That position could be either at thecenter of the target (102), (112), or other select position to achievethe optimum flux profile or light profile.

An advantage of one or more embodiments of the invention is that itpermits the light of the main beams (108) to stay on target withouthaving to take those main beams off sun or off their target to determinethe direction in which they are pointing. This is made possible by thecorrelation between the locations of the signal beam (116) and the mainbeam (108).

An example of some of the calculations involved in one or moreembodiments of the invention are depicted in FIGS. 4A and B. The toppart of FIG. 4A (400) shows a properly oriented heliostat mirror (104)at a first sun angle (402), and the bottom part of FIG. 4B (404) showsan improperly oriented heliostat mirror (104) at a different sun angle(406).

Each individual heliostat mirror (104) is capable, when properlyoriented (400), of receiving incident sunlight from a sun incidentvector (106) and reflecting the majority of the sunlight (402) outwardat a desired main beam (108) to a receiver (102). Note however that whenthe heliostat mirrors (104) are improperly oriented (404), the majorityof the sunlight (406) will be reflected outward along a non-desired mainbeam (108) to a non-desired location or target.

The method used in accordance with one or more embodiments of theinvention involves rigidly connecting at least one optical element (114)to the individual heliostat mirrors (104), where again each opticalelement (114) produces a signal beam of light (116) directed outwardfrom the individual heliostat mirror (104). Note that here, regardlessof the type of optical element used (e.g. elements (114), (202), (204),(200), or other), the optical element operates by taking the incidentsunlight (106) as an input and then producing signal beam light (116) asan output.

Assuming specular reflection, which is normally the case for heliostatmirrors, then the normal vector to the heliostat mirror surface is(405), and the angle of the incident sunlight (106) relative to thenormal vector (405) is equal to the angle of reflection of the main beam(108) relative to the normal vector (405). However, for the opticalelement (114), the angle of the normal vector (415) to its surface willtypically be different from the angle of the normal vector to theheliostat mirror (405) by about a degree. That is, if the angle ofnormal vector (405) is 45 degrees, then the angle of normal vector (415)may be about 46 degrees. As a result, the angle of incidence of thesunlight (106) onto the optical element will differ by about a degree,and using the rule that the angle of incidence is equal to the angle ofreflection, then the angle of the signal beam (116) will differ from theangle of the main beam (108), resulting in the signal beam beingdirected at signal beam target (118) at a different angle.

For these methods, the relative spatial locations or geometry of theheliostat mirrors (104), the receiver (102), and the target (118) orcameras (120) is also important.

The further away the receiver (102) and target (118) is from theheliostat, the greater the offset is between the signal beam (116) andthe main beam (108). To illustrate this point, it is convenient to viewthe situation in terms of standard physics vectors, where the main beam(108) can be considered as a vector, and the signal beam (116) can alsobe considered as a “tracking” vector.

The signal beam or tracking vector (116) can be viewed as being relatedor offset from the main beam vector (108) by a correction vector (408).This correction vector differs according to the distance between theheliostat (104) and the receiver (102) and target (118), as well as thesun angle and the offset between the signal mirror (114) and theheliostat main mirror (104). A calibration process, such as one usingthe previously mentioned jigs, can normally determine this offset. Othercalculations, to be described, are required in order to determine thecorrection vector for each individual heliostat mirror and signal mirrorcombination.

In one or more aspects of the invention, at least one optical sensor(120) or (122) is also positioned in or near the array of heliostatmirrors, and this at least one optical sensor is used to detect thesignal beam of light (116) and determine the tracking vector (116). Inat least one configuration, the signal beam of light (116) impinges on areference surface, such as the target (118), and the optical sensor cansimply be an optical camera or digital camera (122) set to observe thisreference surface (118). In other configurations, as previouslydescribed, the signal beam of light (116) may directly impact on anarray of optical sensors or digital cameras (120) positioned at thetarget (118). Here the individual heliostat mirrors (104) and theirassociated signal beams (116) may be distinguished from each other usingthe previously discussed signal beam modulation methods.

In either case, the signal from the optical sensor or sensors (120) or(122) can, with the aid of a digital computer or computer processingsystem (410), be used, in conjunction with the previously determinedoffset, to determine the correction vector (408). This in turn can beused to compute the main beam vector (108), and determine if the mainbeam (108) is hitting the target (102) properly or not. As previouslydiscussed, often the digital image signals from multiple optical sensorsor digital cameras (120) may be analyzed in order to compensate forsignal beam spread or “sun spread” (417) that may occur as the signalbeam travels from the heliostat to the optical sensor (120).

A key variable in these computations is the position of the sun (402),(406) which varies according to both time of day and the day of theyear. The position of the sun also varies according to latitude as well,but here latitude will be constant for any given heliostat array, sothese effects can be simply compensated for through a latitude offset.

Thus to determine the optimum angle to set the heliostat actuators (110)in order to have the main beam (108) hit the target (102), (112), acomputer processor (410) controlling the actuator (110), by a network orcommunications line (412) will perform a computational process. Thisprocess will typically use the laws of reflection (e.g. angle ofincidence is equal to the angle of reflection). As well as the knowngeometry of the heliostat (104) and the receiver (102). Here the angleof the incident sunlight, or sun incident vector (106) is a known factorthat can be calculated from the time of day, day of the year, andlatitude. Alternatively, the angle of the incident sunlight or sunincident vector (106) can be determined directly by a sun angle sensor,such as an optical device that directly measures the angle of the sunwithout further need for time of day or day of year or latitudecalculations.

The present orientation of the heliostat mirror can be computed from theoptical sensor data ((120), (122) communicated by network orcommunications line (414) or (416)) to the computer (410); and thepreviously determined offset, and used to compute a correction vector(408). The relative locations and geometry of the heliostat mirror (104)relative to the target (102) will usually also be previously determinedand entered into the computer system. Alternatively, these relativelycomplex calculations can be pre-computed and stored in a computer systemas a lookup table or function. These methods may also be done manually,if desired.

In practice, since the layout of the heliostat field, the offsetcalibration of the individual heliostat optical elements (114), and theposition of the sun in the sky at any given day and time can bedetermined in advance, these calculations can also be made in advance ifnecessary, and a multidimensional table of what the ideal signal beamposition is for any given heliostat in the field is at a given time anddate can be generated. This multidimensional table may also contain aseries of heliostat actuator (110) correction values that may be sent tothe actuator in the event that the signal beam is falling into variousnon-ideal values. Other methods, such as real-time physics calculations,functions, and the like may also be used.

Regardless of calculation methods, the calculations make use of a tableor algorithm that takes heliostat identification number, time, date (orobserved sun angle), and observed (actual) signal beam location asinputs, and produces heliostat actuator (110) correction values asoutputs.

Thus using the data obtained from one or more embodiments of theinvention, standard geometrical optics considerations, the previouslyentered layout of the heliostat field, the previously entered offsetdata, and sun angle sensor data, or sun tables or functions showing thesun angle (106) (402), (406) at any given day and time; typically thecomputer system (410) can then perform the suitable geometric opticscalculations and determine the heliostat actuator setting (110) thatwill optimally focus the main beam (108) onto the target (102), as shownin (400). If the heliostat is oriented at an improper angle (404), theoptical sensors (122), (120) will detect this improper angle, feed thedata to the computer system or processor (410), and the processor willsend a notification to an operator for manual adjustment or a correctivesignal to the heliostat actuator (110) via a network, communicationsline, wireless signal, or other communications means (412). Thepreviously discussed signal beam spread is shown in (417), and in someembodiments, the computer system or processor (410) will take imagesfrom multiple cameras and further refine its calculations by computingthe centroid and/or edges of the signal beam spread (417).

Using these methods, an entire heliostat array may be calibrated andreadjusted as often as desired, or indeed on a nearly continual basisthroughout the day, thus insuring that the heliostat array is alwaysfunctioning with peak efficiency. Note that using these methods, thereis essentially no “off sun” time for any heliostat because minorheliostat tracking errors can be caught early and quickly adjustedbefore any significant loss in efficiency occurs.

An example of a suitable computer or processor controlled heliostatcorrection algorithm for a heliostat array is shown in FIG. 5. This isessentially a repeating loop that individually calibrates each heliostatin the array, and then repeats this calibration process at the desiredfrequency. In this example, the heliostat array calibration is assumedto start at heliostat mirror 1, and continue for every numberedheliostat mirror “x” until all heliostat mirrors are calibrated, andthen terminate or repeat as desired. (The algorithm terminationconditions are not shown, and in practice, in one or more embodiments,when the last heliostat in the field is calibrated, the process couldsimply begin again at heliostat mirror 1.) Alternatively, heliostatmirrors known to be more problematic could be given higher priority.Many other schemes (daily calibration, weekly calibration) are alsopossible and within the scope and spirit of the invention.

In this example, the process starts at the first heliostat (500), whenthe open loop feedback algorithm is initialized. Next, in step (502),for each actuator controlled heliostat, the signal beam (116) for theheliostat is measured by the optical sensors (120), (122) and this datais fed into the computer or processor (410). The individual heliostatbeams may optionally be distinguished from each other using thepreviously discussed signal beam modulation methods. Once the signalbeam from a particular heliostat “x”, with a known location in theheliostat field, is detected, the system then compares the actualheliostat signal beam image versus the table or function of idealheliostat settings for that particular heliostat, day, and time (504),and determines (506) if the signal beam is off of position. If thesignal beam is off position, the computer or processor system (410) thencomputes the proper heliostat actuator setting to send to thatparticular heliostat's actuator (110), and then sends the signal to theactuator via network or communications means (412) (508). Regardless ofif that particular heliostat's actuator needs correction or not, oncethis determination is made and usually the correction then done, thesystem will then typically go on to measure and adjust the nextheliostat in the heliostat field (510).

Although implementing this closed loop tracking system and process byone or more computers or processors (410) will generally be quicker andmore convenient, in principle the entire process can be accomplished bypurely manual methods. For example, human operators can determine signalbeam (116) angles and vectors, consult a reference table or book, andthen manually adjust the orientation of the individual heliostatmirrors. In this case, human eyes can take the place of optical sensors(120), (122), and humans can also take the place of the computer andnetwork or communications systems (410), (412), (416).

OTHER EMBODIMENTS

As previously discussed, although the signal beam can conveniently beproduced using sunlight as a source, this is not the only way to producesignal beams. In alternative embodiments, the entire heliostat mirror,if desired, can be induced to produce signal beams using artificiallight sources, and the use of signal mirrors is not necessary. Note thatparticularly when artificial light sources are used, this light need notalways be optical light observable by the human eye. Alternatively,other light frequencies, such as near infrared light, far infraredlight, or even ultraviolet light, may be used. If light not observableby the human eye is used, it may be preferable to use an artificiallight source with a wavelength chosen to better distinguish theartificial light wavelengths from the wavelengths of sunlight, the bluesky, and/or from the background thermal wavelengths of the heliostat andheliostat array. One useful way to do this is to use an extremelybright, short duration, artificial light source, such as a strobe lightor other high intensity light source. An additional advantage of thestrobe light effect is that the timing of the strobe lights can bechosen, for example by a computer system, to uniquely identify eachindividual light source as well. That is, light source 1 can alwaystrigger at time 1, light source 2 can always trigger at time 2, and soon.

FIG. 6 shows an example of this artificial light source embodiment. Inthis example a number of artificial light sources and digital cameras(600), (602), (604) are mounted on elevated poles (606) at variouslocations in a heliostat array (100). In particular, note thatartificial light (608) from light source/digital camera source (600) isreflecting off of the entire heliostat mirror (610) and this resultinglow intensity signal beam (612) is being detected by the camera on lightsource/camera unit (602). Similarly, artificial light (614) fromartificial light source/digital camera (602) is reflecting off ofheliostat mirror (616) and this resulting low intensity signal beam(618) is being detected by the light source/camera unit (604). Theseartificial light sources will often be light emitting diodes,incandescent light sources, fluorescent light sources, and the like.Although collimated artificial light sources such as lasers may be used,omni-directional light sources are also suitable for this embodiment.

If lasers are used, it may be useful to position the lasers in a knownlocation and scan the lasers across the heliostat field while keepingtrack of the precise angle of the laser during the scan. This scanningmethod can help the system precisely distinguish which heliostat isbeing illuminated at any given time, because typically only oneheliostat will be illuminated at each particular laser angle. In thiscase, this additional information may help reduce costs and systemcomplexity because fewer optical sensors or digital cameras may then beneeded. The location of the laser on the heliostat mirror is utilized todetermine if the mirror is properly aligned.

In one embodiment of the invention multiple light sources, suitablymodulated as necessary with digital codes, frequency codes, strobetiming, and the like to identify the pole of origin, are impinging onmultiple heliostat mirrors from multiple poles, and being observed frommultiple camera angles. As a result, using suitable geometric opticalconsiderations (i.e. location of the elevated pole light source/sensorsin the field, location of the heliostat mirrors in the field), theprecise orientation of the heliostat mirrors may be determined. In turn,since the sun angle can be precisely determined either by directmeasurement from sun angle sensors, or from time of day, day of year,and latitude data, once the present angle of the heliostat mirror isdetermined, and once the sun angle is determined, then the system candetermine how best to orient the heliostat mirror in order to have themain heliostat beam (108) hit the receiver (102) in the desiredlocation. Usually the closed loop method and system will use acomputerized control such as computer (410) connected to sensors (600),(602), (604), and controlling the heliostat actuators (110) (not shownin FIG. 6).

The actual distribution of optical sensors and light sources may vary asa function of latitude. In northern hemispheres, typically the sun willbe shining from the south, and the heliostat mirrors in turn will tendto be oriented towards the south, and the distribution of opticalsensors and light sources can be set to be optimized for that region ofthe sky where the sun spends most of the time. In the southernhemisphere, the opposite distribution will apply. To reduce costs, thedistribution of optical sensors and light sources can also be optimizedto concentrate on heliostat mirror positions when the sun is at theangles most likely to be used during peak hours of power production, andthe numbers of cameras covering less optimal sun angles can bedeemphasized.

Although just sensing the presence or absence of a particular artificiallight source in a heliostat mirror, given suitable light source/camerageometry, is generally adequate to determine mirror position to withinabout one degree of accuracy, by using the digital camera to determineexactly where in the particular heliostat mirror (note that signalmirrors are not needed in this embodiment, and thus the entire heliostatmirror is available for scanning) the light source is observed (usuallythe light source will look like a point of light originating from some(x,y) Cartesian coordinate in the mirror), a much higher degree ofaccuracy may be obtained.

In this higher accuracy approach, camera sensors (in this examplemounted on (600), (602), (604) should have an optical system and a CCDor other photodetection array with enough resolution to visualize thevarious heliostat mirrors in their field of responsibility as an imagethat is spread over a fair number of camera pixels. Usually at minimum,the image of a heliostat of interest will be spread over at least a 10pixel by 10 pixel area, and the image of the heliostat of interest willbe preferably spread over a higher level of resolution, such as a 50pixel by 50 pixel area or more.

In this higher resolution scheme, the image of a light source ofinterest, such as (602), will be visualized as a small pinpoint of lightlocated in a particular heliostat (x, y) coordinate.

This is shown in more detail in FIG. 7, which essentially is a close upof part of FIG. 6. Here a heliostat mirror (104), (616) is beingilluminated from an artificial light source (614) from pole (602) (notshown), and the low intensity signal beam (618) is detected by the lightsource/camera unit (604).

Inset (700) shows a portion of the field of view of the digital cameraon pole (604). Here the digital camera will typically image multipleheliostats, including the heliostat of interest, heliostat 616. Theimage of the heliostat mirror (616), as seen by the digital camera, isshown as (702). As can be seen, the image of the artificial light source(614) is shown as a bright spot or pinpoint of light localized to aparticular (x,y) coordinate on heliostat mirror (616). This is shown as(704).

This method of using the pixels of the camera to determine the relativeheliostat mirror (x, y) position of the reflected artificial lightprovides a large amount of additional high precision angularinformation. As for the other methods, this heliostat mirror angularinformation data is then correlated with the sun tracking information,and used to determine the position of the mirror at that moment.

In one example, a heliostat array of thousands of mirrors may becalibrated and adjusted using a system composed of sixty artificiallights, and sixty cameras. These lights and cameras may be mounted onpoles, such as illustrated in FIGS. 6, and 7, or may be mounted in manyother means and arrangements, including mobile arrangements, as well.Here we will continue to use the numbering system from FIGS. 6 and 7.

The impact of measuring the (x, y) position of the reflected artificiallight in the heliostat mirror upon accuracy determinations can be highlysignificant. In the embodiment of the invention that operates withoutmeasuring (x, y) position, i.e. that operates by observing the heliostatarray, and simply determining that, for example, for heliostat mirror(616), camera (604) can (or cannot) detect artificial light number(602), the system can already use standard geometrical optics tocalculate the angle of heliostat mirror (616) to about a degree ofprecision. This is quite good, and already quite an improvement over thepresent art. However by going one step further, and additionallydetecting exactly where in the (x, y) coordinate system of heliostatmirror (616) light (602) is appearing, the system can operate at almost100× higher accuracy, thus providing heliostat angular data down toabout 1/100 of a degree.

Alternatively, this higher level of resolution can also be used toreduce the number of artificial light/camera systems needed to track theheliostat array, and thus help reduce system costs.

Although mounting cameras and artificial light sources on poles has beenused as an example, it should be clear that many other configurationsare possible and are keeping with the spirit of the invention. Aspreviously discussed, as one alternative, the light sources (and orsensors) may be mounted on mobile platforms, such as rotating platforms,and these platforms moved over the heliostat field in a location versustime predictable manner.

An example of this mobile light source or mobile sensor approach isshown in FIG. 8. Here one or more image capture devices (122), such asdigital cameras, are again mounted in one or more locations in theheliostat array. However rather than putting the artificial light sourcenear the camera, as was the case in the previous example, here theartificial light source is mobile. In this example, the artificial lightsources (800) are mounted on the sides of a rotating beam (802)suspended above the heliostat field on a pole or support (804). Althoughthe beam is rotating, the position of the light sources at any giventime can still be precisely known by way of an encoder device (806)attached to the rotating beam, that can precisely determine the angleand position of the light source (800) on rotating beam (802) at anygiven time, and send this information to a computer or processor (410)(not shown).

The other operating methods of this embodiment are otherwise similar tothe embodiment shown in FIGS. 6 and 7. As before, a beam of light (808)from the light source (800) impinges upon heliostat mirror (104), andthe low intensity signal beam (810) reflected from heliostat (104) iscaptured by digital camera or sensor (122). This information is againfed into a computer or processor (410) (not shown). As before, using adigital camera system (122) that can determine the (x, y) position ofthe reflected light in the heliostat mirror is useful because it canallow heliostat angle measurements to be extremely accurate.

The advantage of the rotating beam approach is that because the lightsource is moving, this allows the reflected light to cover multipleregions of the heliostat of interest. Thus, for example, if the (x, y)location of the reflected light in the heliostat mirror is observed bythe digital camera (122) as a function of time, the (x, y) reflectedlight coordinates will trace a pattern over the heliostat surface. Thiswill help average out distortions and errors caused by irregularities inthe heliostat surface, as well allow for sampling a much greater portionof the heliostat surface, which will result in even more accurateheliostat angle determinations.

Whichever type of artificial light source is adopted for use, the key isthat the intensity of the artificial light source is such that it can beobserved by the digital cameras through the day inclusive of thebrightest part of the day. In one or more embodiment of the inventionthe artificial light is replaced with a reflecting element which can beeasily observed even when the sun is at its most intense point in theday. To assist with identifying the reflecting element a black cover mayrotate around the reflecting element and thereby provide a blink ratethe digital cameras can observe. If further intensity is needed toobserve the reflecting element a light source can be directed on thereflecting element which in turn enhances the visibility of thereflecting element. An example of this approach is shown in FIG. 9.

One or more image capture devices (905), such as digital cameras, areagain mounted in one or more locations in the heliostat array (100). Oneor more reflecting elements (901, 902) are located in a heliostat array(100). The reflecting elements may have a bright white surface or anyother surface suitable for reflecting light. Reflecting elements may bemounted on a pole or other support. Rotating masking covers (903, 904)are configured to provide a blink rate the image capture devices (905)can observe. For example, a rotating masking cover (904) may be designedwith a gap such that light reaching reflecting element (902) isreflected as an oscillating beam (910). Mask covers (903, 904) may bedesigned to direct oscillating beams (910, 913), such as at an angle.For example, a rotating mask cover (904) may direct oscillating beam(910) over a conical path (908). Oscillating beams (910, 913) arereflected by heliostat mirrors (104) as periodic signal beams (911,914). Periodic signal beams (911, 914) have a periodic blink ratedetermined by the rotation speed of the rotating mask covers (903, 904).Image capture devices (905) distinguish periodic signal beams (911, 914)from main heliostat beams (108) and incident sun light (106) based onthe periodic nature of the periodic signal beams.

In another embodiment of the invention, artificial light sources (906)may be directed on a reflecting element (901). These artificial lightsources may be collimated or omni-directional. These artificial lightsources will often be light emitting diodes, incandescent light sources,fluorescent light sources, and the like. Although artificial lightsource (906) is shown fixed to the ground, one of ordinary skill in theart would appreciate that the artificial light source (906) may beattached to another surface. Although collimated artificial lightsources such as lasers may be used, omni-directional light sources arealso suitable for this embodiment.

What is claimed is:
 1. A closed-loop tracking system comprising: aplurality of heliostats, wherein each of the plurality of heliostatscomprises a mirror configured to generate a main beam and an opticalelement configured to generate a signal beam at an angular offset fromsaid main beam, wherein each signal beam is spread over a range ofangles; a receiver configured to concurrently receive the main beam fromeach one of the plurality of heliostat mirrors; and a signal beam targetto concurrently receive the signal beam from each one of the pluralityof optical elements, wherein the signal beams from the plurality ofoptical elements are concurrently transmitted to and received by thesignal beam target.
 2. The closed-loop tracking system in claim 1,wherein each of the signal beams varies in color over the range ofangles.
 3. The closed-loop tracking system of claim 2, furthercomprising an array of optical sensors configured to read said signalbeams concurrently received at said signal beam target.
 4. Theclosed-loop tracking system of claim 3, wherein said array of opticalsensors are coupled to said signal beam target.
 5. The closed-looptracking system of claim 4, further comprising a computer configured toreceive sensor data from said array of optical sensors and to control anorientation of said mirrors.
 6. The closed-loop tracking system of claim5, wherein said computer is configured to determine if said mirrors areat an optimal position by using solar angle data as determined either bya solar angle sensor or by at least time and date.
 7. The closed-looptracking system of claim 5, wherein said computer is configured todetermine if said mirrors are at an optimal position by using data thatincludes relative spatial locations of said mirrors, said receiver, andsaid array of optical sensors.
 8. The closed-loop tracking system ofclaim 2, wherein each of said plurality of optical elements comprises anartificial light source configured to produce said signal beam byilluminating a corresponding mirror, causing said mirror to emit saidsignal beam at the angular offset from said main beam.
 9. Theclosed-loop tracking system of claim 2, wherein each of said pluralityof optical elements comprises an artificial collimated light sourcecoupled to a corresponding mirror, said artificial collimated lightsource configured to produce said signal beam at the angular offset fromsaid main beam.
 10. The closed-loop tracking system of claim 2, whereineach one of said signal beams has unique characteristics identifying itto the corresponding one of said plurality of mirrors.
 11. Theclosed-loop tracking system of claim 2, wherein each one of said signalbeams has unique identification information encoded therein to identifyit to the corresponding one of said plurality of heliostat mirrors. 12.The closed-loop tracking system of claim 3, wherein said array ofoptical sensors comprises one or more digital cameras located away fromsaid signal beam target and directed toward said signal beam target. 13.The closed-loop tracking system of claim 5, further comprising one ormore actuators coupled to each one of said plurality of mirrors, whereineach of said one or more actuators is configured to be capable oforienting said one of said plurality of mirrors to a desired angularposition.
 14. A closed-loop tracking system comprising: a plurality ofheliostat mirrors; a plurality of signal mirrors, wherein each one ofsaid plurality of signal mirrors is coupled to a corresponding one ofsaid plurality of heliostat mirrors; a receiver configured to receive amain beam of sunlight reflected from each one of said plurality ofheliostat mirrors; and a signal beam target to receive a signal beamfrom each one of said plurality of signal mirrors, wherein said signalbeam is directed at an angle other than that of said main beam, whereineach signal beam is spread over a range of wavelengths, wherein thesignal beams from the plurality of signal mirrors are concurrentlytransmitted to and received by the signal beam target.